Authentication and information system for reusable surgical instruments

ABSTRACT

An authentication and information system for use in a surgical stapling system includes a microprocessor configured to demultiplex data from a plurality of components in the surgical system. The authentication and information system can include one wire chips and a coupling assembly with a communication connection.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/781,026, filed on, Feb. 4, 2020, now U.S. Pat. No. 11,144,495, whichis a continuation of U.S. patent application Ser. No. 16/420,283, filedon May 23, 2019, now U.S. Pat. No. 10,585,839, which is a continuationof U.S. patent application Ser. No. 16/160,551, filed on Oct. 15, 2018,now U.S. Pat. No. 10,303,641, which is a continuation of U.S. patentapplication Ser. No. 14/670,837, filed Mar. 27, 2015, now abandoned,which claims the benefit of and priority to U.S. Provisional PatentApplication Ser. No. 61/989,609, filed May 7, 2014. The contents of eachof the above applications are hereby incorporated by reference.

BACKGROUND Technical Field

The present disclosure relates to surgical instruments having a reusablehandle and removable and replaceable components, such as a disposable orreplaceable loading unit. The present disclosure relates to printedcircuit boards suitable for use in surgical devices. More particularly,the present disclosure relates to a communication protocol for a systemin which data is communicated through a bus, the protocol eliminatingthe need for multiple buses for transmitting information from variouscomponents in the system.

Description of Related Art

Powered surgical instruments for use in endoscopic procedures are known.Typically, such instruments include a reusable handle assembly, and areplaceable and generally disposable component sometimes referred to assingle use loading unit or SULU. An adapter assembly connects theloading unit, which can include an end effector for interacting withtissue, to the handle assembly. In the case of a surgical stapler, theend effector/tool assembly can include a replaceable cartridge that ischanged after each firing of the surgical stapler. To reduce costs andshorten procedure times, the handle assemblies are generally configuredfor use with a variety of loading units and/or assemblies of variousconfigurations for use on tissue having different properties, e.g.,thickness and density. For example, the different loading units may havestaples of different sizes and/or the staples may be arranged indifferent configurations. To ensure the handle assembly is programmed tooperate with the attached loading unit, some loading units are providedwith an integrated circuit, also known as a chip, that communicates withthe handle assembly to identify the configuration of the loading unit.

Printed circuit boards (PCBs), sometimes referred to as printed wiringboards (PWBs) or etched wiring boards, are widely used in the assemblyof discrete electrical components into operating circuits. PCBsgenerally provide a reliable and economical means of interconnectingelectrical signals among system components. PCBs are available in avariety of different types and may be classified in a variety of ways.

PCBs are generally used to mechanically support and electrically connectelectronic components using electrically-conductive pathways or signaltraces that conduct signals on the PCB. A typical PCB includes one ormore layers of insulating material upon which patterns of electricalconductors are formed. In addition to a pattern of conductive traces onthe PCB, a patterned array of metal-filled through-holes, or vias, maybe formed to allow for layer-to-layer interconnections among variousconductive features.

PCBs may be classified as single-sided PCBs, double-sided PCBs, andmulti-layer PCBs, according to the number of circuit pattern surfaces.PCBs may have circuits that perform a single function or multiplefunctions.

A typical PCB may include a variety of electronic components. Electroniccomponents form parts of electronic circuitry and may be classified in avariety of ways. An electronic component may be classified as active orpassive. In general, an active component is any type of circuitcomponent with the ability to electrically control the flow of electronsor other electrically-charged particles. Some examples of activecomponents are transistors, integrated circuits (ICs), andsilicon-controlled rectifiers (SCRs). Components incapable ofcontrolling current by means of another electrical signal are generallyclassified as passive components. Examples of passive components includecapacitors, resistors, inductors, transformers, and diodes. A PCB onwhich electrical components are mounted is sometimes referred to as aprinted circuit assembly (PCA) or a printed circuit board assembly(PCBA).

Electrical signals may be used on PCBs for controlling the operation ofa surgical device. For example, electrical signals may be used on PCBsfor controlling the delivery of surgical staples to tissue, and may beused for indicatory devices, e.g., to provide feedback to the surgeonrelating to various tissue parameters or conditions. Some surgicalsystems include a powered hand-held surgical device, a surgical loadingunit (sometimes referred to as a disposable loading unit or a disposableend effector), and an adapter for selectively interconnecting thesurgical loading unit and the surgical device. Certain types of adaptersenable the surgical device to drive a multitude of functions of surgicalloading units of various configurations.

In order for the surgical device to drive the various functions of thesurgical loading unit or assembly so that the surgical system performsproperly, a controller may be associated with the surgical device andconfigured to receive various information, such as information about thetype of adapter and/or the type of loading unit. For example, thedifferent surgical loading units may have staples of different sizesand/or the staples may be arranged in different configurations. Toensure the surgical device is programmed to operate with the attachedsurgical loading unit, some reload assemblies are provided with anintegrated circuit, also known as a chip, which communicates with thesurgical device to identify the configuration of the surgical loadingunit.

To ensure the reliability of the surgical system, it is desirable toconfirm whether the surgical loading unit and the adapter have beenpreviously used, and, if so, to count how many times the surgical reloadassembly has been used. Data communications between the surgical loadingunit and the surgical device may pass through a physical connection ofan interface between the adapter and the surgical device.

It would be desirable to develop a communication protocol for use in asurgical system for efficiently and effectively transmitting informationfrom various components in the system.

SUMMARY

In an aspect of the present disclosure, a method of communicating datathrough a bus comprises providing a microprocessor capable ofdemultiplexing transmit and receive lines, providing a first microchipand a second microchip in a surgical system, each of the first andsecond microchips configured to provide authentication of a firstcomponent and a second component in the surgical system, each of thefirst and second microchips being communicatively-coupled through a busto the microprocessor; and controlling a receive mode and a transmitmode over the bus.

The method can further comprise receiving at least one signal from thefirst microchip or the second microchip using the receive mode over thebus. Receiving at least one signal can include selecting the receivemode utilizing the microprocessor. The method can further comprisetransmitting at least one signal to the first microchip or the secondmicrochip using the transmit mode over the bus. Transmitting at leastone signal can include selecting the transmit mode utilizing themicroprocessor.

The method can further comprise providing a third microchip connected tothe microprocessor, the third microchip having a data wire and a groundwire.

The method can further comprise receiving at least one signal from thefirst microchip or the second microchip, including turning on the groundwire of the first microchip or second microchip. The method can furthercomprise transmitting at least one signal from the first microchip orthe second microchip, including turning off the ground wire of the firstmicrochip or second microchip.

In another aspect, a method of communicating data through a buscomprises authenticating a surgical component utilizing a microchipcommunicatively-coupled through a bus to a microprocessor capable ofdemultiplexing transmit and receive lines, and controlling a receivemode and a transmit mode over the bus.

Authenticating can include utilizing the microchip. Authenticating canfurther include utilizing a one-wire data interface of the microchip.

The method can further comprise receiving at least one signal from thesurgical component using the receive mode over the bus. Receiving atleast one signal from the surgical component using the receive mode overthe bus can include turning on the ground wire of the microchip. Themicroprocessor can be used to select the receive mode.

The method can further comprise transmitting at least one signal to themicroprocessor using the transmit mode over the bus. Transmitting atleast one signal to the microprocessor using the transmit mode over thebus can include turning off the ground wire of the microchip.Transmitting at least one signal to the microprocessor using thetransmit mode over the bus can further include utilizing themicroprocessor to select the transmit mode.

In certain embodiments, the surgical component has a second microchip.The microprocessor can be part of a controller for a surgical system,the surgical component being a part of the surgical system.

In another aspect, a surgical system, comprises a handle assembly havinga controller, the controller having at least one program, an adapterassembly, and a loading unit having a tool assembly and at least onechip assembly having a chip storing data indicating whether the toolassembly articulates or not, the controller including a microprocessorconfigured for de-multiplexing data from said chip.

The controller can read the data and not drive an articulation link inthe adapter assembly and/or loading unit if the data indicated that theloading unit does not articulate.

In yet another aspect, a surgical system, comprises a handle assemblyhaving a controller, the controller having at least one program, anadapter assembly, and a loading unit having a tool assembly and at leastone chip assembly having a chip storing data indicating the maximumdrive force for the loading unit, the controller including amicroprocessor configured for de-multiplexing data from said chip.

The controller can be is programmed to read the data, and also read adrive force from a sensor, wherein the controller does not drive amember in the adapter assembly and/or loading unit if the drive forceindicates that the maximum drive force has been reached.

The controller can be programmed to read the data, and also read a driveforce from a sensor, wherein the controller operates in slow mode if thedrive force indicates that the maximum drive force has been reached.

The chip can also store information about the type of loading unit. Theloading unit can include a removable and replaceable staple cartridgeassembly. The removable and replaceable staple cartridge assembly caninclude a chip storing data concerning the staple cartridge assembly

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects, features, and advantages of the presentdisclosure will become more apparent in light of the following detaileddescription when taken in conjunction with the accompanying drawings inwhich:

FIG. 1 is a perspective view of a surgical stapling device for use witha chip assembly according to embodiments of the present disclosure;

FIG. 2 is a perspective view of the surgical stapling device of FIG. 1showing the handle assembly, adapter assembly, and loading unit in aseparated configuration;

FIG. 3 is a view of a proximal end of a loading unit and a distal end ofan adapter assembly of the surgical stapling device shown in FIG. 1 ;

FIG. 4 is an enlarged view of the proximal end of the loading unit andthe distal end of the adapter assembly shown in FIG. 3 ;

FIG. 5 is another enlarged view of the proximal end of the loading unitand the distal end of the adapter assembly shown in FIG. 3 ;

FIG. 6 is an enlarged, exploded view of the proximal end of the loadingunit shown in FIG. 3 with the loading unit and authentication boardseparated;

FIG. 7 is an enlarged, partially-exploded view of the proximal end ofthe loading unit shown in FIG. 3 with the authentication board coverseparated from the loading unit;

FIG. 8 is an enlarged view of the proximal end of the loading unit shownin FIG. 3 ;

FIG. 9 is a perspective view of an authentication board assemblyaccording to an embodiment of the present disclosure;

FIG. 10 is a perspective view of an authentication board contact;

FIG. 11 is an enlarged, exploded view of the distal end of the adapterassembly shown in FIG. 3 with the adapter assembly and adapter boardseparated;

FIG. 12 is an enlarged view of the adapter board shown in FIG. 11 ;

FIG. 13 is another enlarged view of the adapter board shown in FIG. 11 ;

FIG. 14 is yet another enlarged view of the adapter board shown in FIG.11 ;

FIG. 15 is a cross-sectional, side view of the adapter assembly shown inFIG. 3 showing the adapter assembly separated from the loading unit;

FIG. 16 is an enlarged view of the indicated area shown in FIG. 15showing the adapter board separated from the authentication board;

FIG. 17 is a cross-sectional, side view of the adapter assembly shown inFIG. 3 showing the adapter assembly engaged with the loading unit;

FIG. 18 is an enlarged view of the indicated area shown in FIG. 17showing the adapter board engaged with the authentication board;

FIG. 19 is a cross-sectional, axial view of the adapter assembly shownin FIG. 3 showing the adapter assembly separated from the loading unit;

FIG. 20 is a cross-sectional, axial view of the adapter assembly shownin FIG. 3 showing the loading unit inserted into the adapter assembly;

FIG. 21 is a cross-sectional, axial view of the adapter assembly shownin FIG. 3 showing the loading unit engaged with the adapter assembly;

FIG. 22 is a perspective view of a surgical stapling device according tofurther embodiments of the present disclosure;

FIG. 23 is a perspective view of a loading unit according to embodimentsof the present disclosure;

FIG. 24 is the loading unit of FIG. 23 shown with parts separated;

FIG. 25 is a detailed perspective view of a board assembly;

FIG. 26 is a another detailed perspective view of the board assembly ofFIG. 25 ;

FIG. 27 is a detailed perspective view of a chip assembly;

FIG. 28 is another detailed perspective view of the chip assembly ofFIG. 27 ;

FIG. 29 is a detailed perspective view of a support plate in accordancewith embodiments of the present disclosure;

FIG. 30 is a perspective view of the chip assembly and board assembly ofFIGS. 25-28 ;

FIG. 31 is another perspective view of the chip assembly and boardassembly of FIGS. 25-28 ;

FIG. 32 is a top perspective view of a staple cartridge assembly inaccordance with embodiments of the present disclosure;

FIG. 33 is a top perspective view of the staple cartridge assembly ofFIG. 32 , with a shipping wedge;

FIG. 34 is a bottom perspective view of the shipping wedge of FIG. 33 ;

FIG. 35 is a detailed perspective view of a lockout assembly inaccordance with embodiments of the present disclosure;

FIG. 36 is a perspective view of the loading unit of FIG. 23 showing thestaple cartridge assembly;

FIG. 37 is a top view of the loading unit with the anvil and shippingwedge removed;

FIG. 38 is a perspective view of the proximal portion of a support plateof the staple cartridge assembly;

FIG. 39 is a perspective view of the proximal portion of a channel ofthe loading unit;

FIG. 40 is a cross sectional view of the loading unit;

FIG. 41 is a perspective view of a chip assembly of the loading unitwith parts separated;

FIG. 42 is a perspective view of the proximal portion of the loadingunit;

FIG. 43 is a perspective view of the chip assembly;

FIG. 44 is a perspective view of the proximal portion of the loadingunit;

FIG. 45 is another perspective view of the chip assembly;

FIG. 46 is a detailed perspective view of a lockout assembly inaccordance with embodiments of the present disclosure;

FIG. 47 is another detailed perspective view of a lockout mechanism inaccordance with embodiments of the present disclosure;

FIG. 48 is a cross sectional view through the drive beam;

FIG. 49 is a another detailed perspective view of the lockout mechanism;

FIG. 50 is a perspective view with parts separated showing a latch,sled, and mounting portion;

FIG. 51 is a perspective view of the latch;

FIG. 52 is a perspective view of the loading unit with parts removedshowing the lockout mechanism;

FIG. 53 is a perspective view of the lockout mechanism with partsseparated showing the drive beam;

FIG. 54 is a cross sectional view taken longitudinally through theloading unit;

FIG. 55 is a detailed view of FIG. 54 showing the latch and dynamicclamping member;

FIG. 56 is a side view of the drive beam, dynamic clamping member, andsled;

FIG. 57 is a side view of the drive beam, dynamic clamping member, andsled, with the drive beam and dynamic clamping member advanced; and

FIG. 58 is a perspective view of a surgical system in accordance with anembodiment of the present disclosure;

FIG. 59 a circuit diagram of a printed circuit board (PCB) in accordancewith an embodiment of the present disclosure; and

FIG. 60 is a circuit diagram of a PCB in accordance with an embodimentof the present disclosure;

FIG. 61 is a flowchart illustrating a method of communicating datathrough a bus in accordance with an embodiment of the presentdisclosure; and

FIG. 62 is a perspective view of coupling assembly, shown de-coupled,and showing the rotatable drive connectors and communication connectors.

DETAILED DESCRIPTION

Particular embodiments of the present disclosure are describedhereinbelow with reference to the accompanying drawings; however, it isto be understood that the disclosed embodiments are merely examples ofthe disclosure, which may be embodied in various forms. Well-knownand/or repetitive functions and constructions are not described indetail to avoid obscuring the present disclosure in unnecessary orredundant detail. Therefore, specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as abasis for the claims and as a representative basis for teaching oneskilled in the art to variously employ the present disclosure invirtually any appropriately detailed structure. As is common in the art,the term “proximal” refers to that part or component closer to the useror operator, i.e. surgeon or clinician, while the term “distal” refersto that part or component further away from the user. In addition, asused herein in the description and in the claims, terms referencingorientation, e.g., “top”, “bottom”, “upper”, “lower”, “left”, “right”,and the like, are used with reference to the figures and features shownand described herein. It is to be understood that embodiments inaccordance with the present disclosure may be practiced in anyorientation without limitation. In this description, as well as in thedrawings, like-referenced numbers represent elements which may performthe same, similar, or equivalent functions. Embodiments of the presentlydisclosed chip assembly will now be described in detail with referenceto the drawings in which like reference numerals designate identical orcorresponding elements in each of the several views. The word“exemplary” is used herein to mean “serving as an example, instance, orillustration.” Any embodiment described herein as “exemplary” is notnecessarily to be construed as preferred or advantageous over otherembodiments. The word “example” may be used interchangeably with theterm “exemplary.”

This description may use the phrases “in an embodiment,” “inembodiments,” “in some embodiments,” or “in other embodiments,” whichmay each refer to one or more of the same or different embodiments inaccordance with the present disclosure.

As it is used in this description, “printed circuit board” (or “PCB”) or“circuit boards” generally refers systems that provide, among otherthings, mechanical support to electrical devices and/or components,electrical connection to and between these electrical components,combinations thereof, and the like. For the purposes herein, the term“printed circuit board” is interchangeable with the term “printed wiringboard” and either is represented herein by the acronym PCB.

With reference initially to FIGS. 1 and 2 , a surgical staplinginstrument including an authentication system according to the presentdisclosure is shown generally as stapler 10. Stapler 10 includes ahandle assembly 12, an adapter assembly 14 extending distally fromhandle assembly 12, and a loading unit 16 selectively secured to adistal end of adapter assembly 14. A detailed description of handleassembly 12, adapter assembly 14, and loading unit 16 is provided incommonly-owned U.S. Patent Appl. Publ. No. 2012/0089131, the contents ofwhich is incorporated herein by reference in its entirety.

Handle assembly 12 includes a lower housing portion 17, an intermediatehousing portion 18 extending from and/or supported on lower housingportion 17, and an upper housing portion 19 extending from and/orsupported on intermediate housing portion 18. Intermediate housingportion 18 and upper housing portion 19 are separated into a distalhalf-section 20 a that is integrally formed with, and extends from, thelower housing portion 17, and a proximal half-section 20 b joined todistal half-section 20 a by any suitable manner of attachment, such aswithout limitation, ultrasonic welding and/or a plurality of fasteners.When joined, distal and proximal half-sections 20 a, 20 b form a handlehousing 21 defining a cavity therein which houses a circuit board thatincludes a controller 21 a, and a drive mechanism (not shown).

Lower housing portion 17 includes a door 13 pivotally connected theretofor accessing a cavity formed in lower housing portion 17 for retaininga battery (not shown) therein. It is contemplated that stapler 10 may bepowered by any number of power sources, such as, for example and withoutlimitation, a fuel cell, a power cord connected to an external powersource, and so forth.

Adapter assembly 14 includes a drive coupler 22 at a proximal endthereof and a loading unit coupler 15 at a distal end thereof. Distalhalf-section 20 a of upper housing portion 19 defines a nose orconnecting portion 11 configured to operably receive drive coupler 22 ofadapter assembly 14. Loading unit 16 includes an adapter coupler 27configured to operably receive loading unit coupler 15 of adapterassembly 14.

Upper housing portion 19 of handle housing 21 encloses a drive mechanism(not shown) configured to drive shafts and/or gear components (notshown) in order to perform the various operations of stapler 10. Inparticular, the drive mechanism is configured to drive shafts and/orgear components in order to selectively move a tool assembly or endeffector 23 of loading unit 16 relative to a proximal body portion 24 ofloading unit 16, to rotate loading unit 16 about a longitudinal axis“X-X” (FIG. 1 ) relative to handle housing 21, to move an anvil assembly25 relative to cartridge assembly 26 of loading unit 16, and/or to firea stapling and cutting cartridge within cartridge assembly 26 of loadingunit 16.

The loading unit 16 shown in the FIGS. 1-21 is a linear surgicalstapling loading unit. The loading unit includes a stapling anvil withrecesses for forming surgical staples that are driven against it byoperation of the loading unit in the surgical system. A staple cartridgehouses the surgical staples, as well as the staple firing and/or drivingassembly. The staple firing and/or driving assembly is known. One suchassembly is described in U.S. Pat. Nos. 8,256,656 and 7,044,353, theentire disclosures of which are hereby incorporated by reference herein.The drive assembly includes an elongated drive beam having a knifeblade. The drive beam pushes an actuation sled having wedge shapedsurfaces for interacting with pushers. The pushers support the staplesand have camming surfaces that the sled wedge shaped surfaces slideagainst, driving the pushers upwardly while the sled is advanced in alongitudinal fashion through the staple cartridge.

It is contemplated that the loading unit has jaw members for supportingthe anvil and the staple cartridge respectively. The anvil jaw memberand staple cartridge jaw member can be approximated to clamp tissuetherebetween. It is also contemplated that the end effector canarticulate or pivot off axis from the longitudinal axis defined by theproximal body portion 24.

It is contemplated that the loading unit can be a circular surgicalstapling unit, other types of stapling units, or other types of surgicalend effectors, such as electrocautery, ablation, ultrasonic, etc.

With reference to FIGS. 3, 4, and 5 , loading unit coupler 15 of adapterassembly 14 is configured to operably engage adapter coupler 27 ofloading unit 16 via a push and twist or bayonet-type arrangement.Adapter coupler 27 includes one or more bayonet lugs 28 that areconfigured to mate with corresponding one or more bayonet channels 29defined in a bayonet collar 48 provided by loading unit coupler 15 ofadapter assembly 14. A short link member 44 and a load link member 45are longitudinally disposed within adapter assembly 14 and areconfigured to translate longitudinally (e.g., distally and proximally)during operation of stapler 10. A cam 55 disposed at a distal end ofshort link member 44 is urged distally against a bayonet channel 29 byspring 49 a. To engage loading unit 16 with adapter assembly 14, adaptercoupler 27 of loading unit 16 is inserted into loading unit coupler 15of adapter assembly 14 and rotated. In turn, bayonet collar 48 rotatescooperatively with adapter coupler 27. As bayonet collar 48 rotates, cam55 rides off bayonet channel 29, causing short link member 44 totranslate distally, which, in turn, causes a switch tab 47 formed inshort link member 44 to actuate switch 46. Switch 46 is in operativeelectrical communication with the controller 21 a and is configured toconvey thereto the engagement status between loading unit 16 and adapterassembly 14.

Turning now to FIGS. 6-10 , adapter coupler 27 of loading unit 16includes an authentication board assembly 30 that is configured to besecurely mounted within a recess 31 defined in adapter coupler 27.Authentication board assembly 30 is positioned within adapter coupler 27such that when loading unit 16 is secured to adapter assembly 14,authentication board assembly 30 engages an adapter board assembly 50mounted within loading unit coupler 15 of the adapter assembly (FIG. 11). In more detail, authentication board 30 includes a circuit board 37,a pair of contact members 40 a, 40 b (collectively, contact members 40)and a chip 36. Circuit board 37 defines a substantially planar elongatedmember configured to be securely received within recess 31 defined byadapter coupler 27. Chip 36 is in electrical communication with contactmembers 40. A distal end 37 a of circuit board 37 supports chip 36, anda proximal end 37 b of circuit board 37 supports contact members 40.Distal end 37 a of circuit board 37 includes an alignment notch 33defined therein that is configured to engage a corresponding alignmentnub 32 provided at a distal end of recess 31 to ensure secure andaccurate positioning of authentication board assembly 30 within adaptercoupler 27.

Chip 36 includes any chip capable of storing the specifications ofloading unit 16, such as, without limitation, cartridge size, staplearrangement, staple length, clamp-up distance, date of manufacture,expiration date, compatibility characteristics, a unique identifier(e.g., a serial number), and/or number of uses, and transmitting thespecifications to handle assembly 12. In some embodiments, chip 36includes an erasable programmable read only memory (“EPROM”) chip. Inthis manner, the handle assembly 12 may adjust the firing forces, firingstroke, and/or other operational characteristics thereof in accordancewith the specifications of loading unit 16 that are transmitted fromchip 36. It is further envisioned that chip 36 may include writecapabilities which allow handle assembly 12 to communicate to chip 36that the associated loading unit 16 has been used, which can preventreloading or reuse of an expended reload assembly, or any otherunauthorized use.

In some embodiments, chip 36 includes a secure authentication chip, suchas, without limitation, a DS28E15 DeepCover™ Secure Authenticator with1-Wire SHA-256 and 512-Bit User EEPROM, manufactured by MaximIntegrated™ of San Jose, Calif. In these embodiments, the contents ofchip 36, and the communications between chip 36 and handle assembly 12,are encrypted to prevent unauthorized access. In this manner, the use oflow-quality counterfeit, re-manufactured, or “knock-off” loading unitsis effectively discouraged, which, in turn, reduces risk to patients byensuring that only fresh, authentic loading units 16 are used duringsurgical procedures. In addition, the likelihood that medical facilitiesand/or surgeons may unwittingly use counterfeit loading units is greatlycurtailed, thus reducing the overall costs to society for deliveringmedical services. In some embodiments, chip 36 utilizes a “1-wire”communications interface whereby a single signal conductor is employed,together with a ground conductor, for bidirectional serialcommunications between chip 36 and handle assembly 12.

Contact assembly 38 (FIGS. 9, 10 ) includes a short contact arm 41 and along contact arm 42 joined by a contact base 59, and having a generallyelongated u-shaped configuration. Short contact arm 41 includes a firstcontact member 40 a orthogonally disposed and fixed to an upper portionof a proximal end thereof. Long contact arm 42 includes a second contactmember 40 b orthogonally disposed and fixed to an upper portion of aproximal end thereof. Short and long contact arms 41, 42 each include asolder tab 39 orthogonally disposed and fixed to a lower portion of adistal end thereof. Solder tabs 39 are electromechanically joined to aproximal end 37 b of circuit board 37 by, e.g., soldering, electricallyconductive adhesive, and/or other suitable technique.

Adapter coupler 27 includes a raised contact support 34 extendingradially from a proximal end thereof and includes a pair of cradles 35a, 35 b defined therein that are configured to receive first contactmember 40 a and second contact member 40 b, respectively, whenauthentication board assembly 30 is positioned within recess 31 ofadapter coupler 27. A cover 43 is configured to enclose and retainauthentication board assembly 30 within recess 31 of adapter coupler 27(FIGS. 7 and 8 ).

In some embodiments, short contact arm 41 and first contact member 40 aare electrically insulated from long contact arm 42 and second contactmember 40 b by contact base 59. In these embodiments, each of shortcontact arm 41 and long contact arm 42 carries a separate circuit, e.g.,short contact arm 41 carries signal and long contact arm 42 carriesground. In other embodiments, short contact arm 41 and first contactmember 40 a are electrically joined with long contact arm 42 and secondcontact member 40 b. In these embodiments, short contact arm 41 and longcontact arm 42 operate in a bifurcated or redundant mode to carry asignal circuit, while the ground circuit is carried through otherelectrically conductive components of loading unit 16, adapter unit 14,and/or handle assembly 12.

As mentioned above, authentication board assembly 30 is configured toengage adapter board assembly 50 mounted within loading unit coupler 15when loading unit 16 is secured to adapter assembly 14. With referencenow to FIGS. 11-14 , loading unit coupler 15 includes an adapter boardassembly 50 that is configured to be floatingly mounted within a pocket60 defined in loading unit coupler 15. Adapter board assembly 50 ispositioned within loading unit coupler 15 such that when loading unit 16is secured to adapter assembly 14, adapter board assembly 50 engagesauthentication board assembly 30.

Adapter board assembly 50 includes a circuit board 51 having a pair ofcontact members 55 a, 55 b (collectively, contact members 55) fixedthereto and in operable communication with handle assembly 12. In theillustrated embodiment, contact members 55 a, 55 b are arranged foreffective engagement in a transverse direction, e.g., transverse to thelongitudinal axis “X-X” of stapler 10, to accommodate the rotationalcoupling of loading unit 16 and adapter assembly 14 as described herein.

Circuit board 51 includes an upper surface 51 a, a lower surface 51 b, aproximal end 51 c, and a distal end 51 d. Circuit board 51 defines asubstantially planar elongated member configured to be resiliently orfloatingly received within pocket 60 defined by loading unit coupler 15.A spring clip 52 is fixed to a proximal end 51 c of circuit board 51 andis configured to support adapter board assembly 50 within pocket 60.Spring clip 52 includes a pair of spring supports 54 having a wing-likeconfiguration that are configured prevent spring clip 52 fromover-extension and to provide stiffness thereto. Adapter board assembly50 includes a spring 53 having a broad, curvate u-shaped profiledisposed on an upper surface 51 a of circuit board 51. In someembodiments, spring clip 52 and spring 53 may be integrally formed.Spring clip 52 and/or spring 53 may be positively aligned and/orsupported by a notch 62 defined in proximal end 51 c of circuit board51. Circuit board 51 includes one or more through holes 56 definedtherein that may be utilized to form a conductive pathway between uppersurface 51 a and lower surface 51 b of circuit board 51.

When adapter board assembly 50 is mounted within pocket 60, spring 53bears against outer tube 57 of adapter assembly 14 (FIGS. 15, 16 ). Inuse, adapter board 50 is spring-biased towards authentication boardassembly 30 by spring 53 and by side spring clip 52 such that, uponjoining loading unit 16 and adapter assembly 14, any manufacturingtolerances between loading unit 16 and adapter assembly 14 arecompensated for by engagement of the floating spring mount of adapterboard 50 within pocket 60. In this manner, a reliable connection betweencontact members 55 of adapter board 50 and contact members 40 ofauthentication board assembly 30 is consistently achieved, thusproviding a robust communication link between chip 36 and handleassembly 12. In embodiments, contact assembly 38, contacts 40, and/orcontacts 55 are formed at least in part from electrically conductivematerial, such as, without limitation, beryllium copper.

Turning now to FIGS. 15-21 , the interaction between adapter boardassembly 50 and authentication board assembly 30 is shown. As seen inFIGS. 15, 16, and 19 , adapter board 50 is retained within loading unitadapter 15 by spring clip 52. Spring 53 bears against outer tube 57 tobias adapter board 50 inwardly towards bore 61, such that contactmembers 55 extend into bore 61. As adapter coupler 27 is inserted fullyinto bore 61 of loading unit adapter 15, the initial rotationalorientation of adapter coupler 27 and loading unit coupler 15 is suchthat contact members 40 of authentication board 30 and contact members55 of adapter board 50 are roughly 45° apart (FIG. 20 ). As loading unit16 is rotated with respect to adapter assembly 14, contact members 40 ofauthentication board 30 are brought into engagement with contact members55 of adapter board 50. Advantageously, contact support 34 of adaptercoupler 27 of loading unit 16 provides radial support to contact members30 as they engage mating contact members 55 of adapter board 50. Inaddition, spring 53 bears against outer tube 57 which enables adapterboard 50 to float with respect to authentication board 30 and loadingunit coupler 15, thereby compensating for manufacturing variationsbetween the various components and providing a reliable connectionbetween authentication board 30 and adapter board 50.

It is contemplated that a loading unit like loading unit 16 could have aremovable and replaceable staple cartridge assembly. A stapling systemis shown in FIGS. 22-57 , in accordance with an embodiment of thepresent disclosure, having a powered handle assembly 112 similar to thehandle assembly 12 discussed above. The handle assembly is configured asdiscussed above and has a controller 121 a. The stapling system includesan adapter assembly 114 and a loading unit 116, each of which can beconfigured as discussed above. The loading unit is a linear staplingloading unit, but other types of loading units are contemplated. Theloading unit 116 has a drive assembly for firing staples into tissueclamped between the anvil jaw member 111 and staple cartridge jaw member113, as discussed above.

Supported in the staple cartridge jaw member 113 is a removable andreplaceable staple cartridge assembly 115. A removable and replaceablestaple cartridge assembly is disclosed in U.S. patent application Ser.No. 13/280,880, filed Oct. 25, 2011, and published as US 2013-0098965A1, the entire disclosure of which is hereby incorporated by referenceherein.

Loading unit 116 of the present disclosure is configured to be used morethan once. In particular, the loading unit has the removable staplecartridge assembly 115 that includes the staple cartridge and driveassembly discussed above. The removable assembly 116 is configured to beremoved and replaced (e.g., after firing staples or other surgicalfasteners therefrom). The loading unit 116 shown includes a proximalbody portion 118 that is attachable to the adapter assembly 114.However, the features of the loading units of the present disclosure canbe incorporated in a surgical instrument in which does not include adetachable portion of the elongated portion of the instrument.

Loading unit 500 includes a proximal body portion 118 defining alongitudinal axis “A-A”. Jaw members include an anvil jaw member 111 anda cartridge jaw member 113. One of the jaw members is pivotal inrelation to the other to enable the clamping of tissue between the jawmembers. In the illustrated embodiments, the cartridge jaw member 113 ispivotal in relation to the anvil jaw member and is movable between anopen or unclamped position and a closed or approximated position.However, the anvil jaw member, or both the cartridge and anvil jawmember, can be movable. As discussed in connection with FIGS. 1-21 , theanvil jaw member includes an anvil having a plurality of staple formingdepressions.

The cartridge jaw member 113 includes a channel or carrier 120 whichreceives and supports the staple cartridge assembly 115. The cartridgeassembly has a cartridge body 140 and a support plate 111. The cartridgebody and support plate are attached to the channel or carrier 120 by asnap-fit connection, as discussed below, a detent, latch, or by anothertype of connection. The cartridge assembly includes fasteners or staples141. Cartridge body 140 defines a plurality of laterally spaced stapleretention slots 142, which are configured as openings (see FIG. 32 ).Each slot is configured to receive a fastener or staple therein.Cartridge assembly also defines a plurality of cam wedge slots whichaccommodate staple pushers 146 and which are open on the bottom to allowthe actuation sled 148 to pass longitudinally therethrough in the firingof the staples as discussed above.

The removable staple cartridge assembly 115 includes cartridge body 140and support plate 111. The removable assembly 115 is removable fromchannel 120, e.g., after staples have been fired from the cartridge body140. Another removable and replaceable staple cartridge assembly iscapable of being loaded into the channel, such that the loading unit 116can be actuated again to fire additional fasteners or staples.

Channel 120 includes one or a pair of engagement structures 120 a (suchas slots) for engaging the staple cartridge assembly and support plate(see FIG. 39 ), a central slot for the passage of the drive beam, a pairof proximal holes 150 for connection with the anvil jaw member, and aramped surface 152. Proximal holes 150 are configured to alignwith/mechanically engage a pair of corresponding holes or features onthe anvil jaw member. The jaw members can be connected by pins, forexample, to facilitate a pivotal relationship between anvil jaw member111 and cartridge jaw member 113.

The cartridge body 140 includes a central slot 143, and rows of stapleretention slots positioned on each side of slot 143 (see FIG. 32 ).Cartridge body also includes a pair of engagement structures orprotrusions which may, in certain embodiments, be slots or openingsadjacent its proximal end for connection with the support plate 111 aand/or channel 120.

With particular reference to FIG. 29 , support plate 111 a includes abase 145, engagement features 147 and 147 a (see FIG. 38 ) forconnection with the cartridge body and/or channel, and a mountingportion 149 at a proximal end thereof (see FIG. 29 ). The support plate111 a is disposed underneath the cartridge body to support the staplepushers, actuation sled, and staples (or other surgical fasteners) andprevent those components from falling out of the staple cartridgeassembly.

The loading unit can include a chip assembly 360 mounted on a proximalend of the proximal body portion 118, as shown in FIGS. 41-45 , forexample. The chip assembly is as described above in connection with theauthentication board assembly 30 discussed above. The chip assembly 360is mounted for connection with a board assembly in the coupler on thedistal end of the adapter assembly 114, and can be configured asdiscussed above in connection with FIGS. 1-21 . The chip assembly 360includes a chip 361 for authentication and information purposes, and caninclude a memory that stores certain information. The information caninclude the type of device the loading unit is, the version of thedevice/loading unit, the name of the loading unit, the manufacturing lotnumber, the serial or other identification number, the maximum force towhich the drive beam of the loading unit can be driven, the interlockzone (mm), the end zone (mm), whether or not the loading unit canarticulate, and/or a usage limit (the number of times the loading unitcan be used). The interlock zone is the position of the drive beam, inmillimeters, measured from the start or initial position of the drivebeam, when the drive beam is engaged by a lockout in the loading unit.The end zone is the position of the drive beam, in millimeters, measuredfrom the start or initial position of the drive beam, when the drivebeam has reached the end of its travel in the staple cartridge body 140.Since the staple cartridge assembly 115 can be removed and replaced,there is an intended limit to the number of times the loading unit canbe reloaded with a fresh unfired staple cartridge. The informationstored on the chip can include the staple line length and/or length ofthe staple cartridge.

The controller 121 a in the handle assembly 112 can be programmed toread the information on the chip 361. This information is used in theoperation of the surgical system. Desirably, some or all of theinformation is encrypted, which can be accomplished as discussed abovein connection with FIGS. 1-21 . The controller can be programmed to notprovide power to a motor (not shown) disposed in the handle assembly112, and not operate the adapter assembly and loading unit, in the eventthat the serial number or other data is not recognized. The maximumforce information is used in conjunction with a load sensor, such as astrain gauge, disposed in the surgical system. For example, a loadsensor can be disposed in the adapter assembly 114 and/or loading unit,such as a load sensor on the drive beam. The controller is programmed tocompare the data from the load sensor to the maximum force data storedon the chip so that, for example, the operation of the motor (not shown)is interrupted before the maximum force is exceeded. In another example,the controller can be programmed to operate in “slow mode” if themeasured force reaches a predetermined level. The predetermined level offorce can be the maximum force discussed above, or another level offorce, stored on a chip in the system, such as chip 361. Slow mode meansthat the controller operates the motor (not shown) at a slower rate,generating more torque, and also delaying the compression of tissueand/or firing of staples. In thick tissue, slow mode can allow fluid inthe tissue to move away from the site of stapling, facilitating morecompression of the tissue.

In a similar manner, the operation of the motor can be stopped oroperated in slow mode if the drive beam is disposed in the interlockzone or the end zone. Furthermore, the controller can interrupt orprevent the operation of the articulation linkage, bar or cable if thedata on chip 361 indicated that the loading unit does not articulate.

It is contemplated that the chip 361 with some or all of the datadiscussed above can be provided in any of the embodiments disclosedherein, including loading units that do not have a removable andreplaceable staple cartridge assembly, and/or loading units that do notarticulate.

It is contemplated that the information on chip 361 can be read by thecontroller in the handle assembly, another chip in the system, or anyother computer component in the surgical system.

In any of the embodiments disclosed herein, the controller can writeinformation to the chip on the loading unit. For example, the maximumforce that was used to clamp onto tissue, as measured by the load sensordiscussed above, the maximum force that was used to fire staples, and/orthe position of the drive beam when the drive beam stops advancing, etc.Other information that can be written to the chip 361 includes thelocation of the drive beam when the device entered into slow mode, thenumber of times the loading unit has been fired, whether the loadingunit has been fired, the type of handle assembly, the serial number ofthe handle assembly, the type of adapter assembly, and/or the serialnumber of the adapter assembly. The maximum force to fire staples can besaved along with the position of the drive beam, in any of theembodiments disclosed herein. The information can also be saved in amemory connected to the controller in the handle assembly, other chipsin the system, or other computer components of the surgical system.

It is also envisioned, in any of the embodiments disclosed herein, thatan end effector or tool assembly is arranged for articulating between afirst position where tool assembly is aligned with longitudinal axis“Y-Y,” and a second position where tool assembly is disposed at an anglewith respect to longitudinal axis “Y-Y.” For example, the tool assembly,which includes the anvil jaw member and the cartridge jaw member, may bemounted so as to be pivotable with respect to the proximal body portion118. The anvil jaw member and cartridge jaw member can be attached to amounting assembly 2020 (discussed further below), and the mountingassembly can be pivotably connected to the proximal body portion 118.The loading unit 116 includes one or more cables or linkages disposed inthe proximal body portion so that when the cable or linkage isdisplaced, the tool assembly pivots and articulates with respect to theinstrument. Further details of providing articulation are described indetail in commonly-owned U.S. Pat. No. 6,953,139 to Milliman et al., thecontents of which are hereby incorporated by reference in theirentirety. The adapter assembly 114 can include a linkage, bar or cablefor enabling the articulation of the tool assembly.

As seen in FIG. 32 , for example, any of the embodiments disclosedherein can include a cartridge body 140 having a steppedtissue-contacting surface 1412. In such embodiments, different sizedstaples, or all the same sized staples, may be used. Further details ofa staple cartridge having multiple staple sizes are included in U.S.Pat. No. 7,407,075 to Holsten et al., the entire contents of which arehereby incorporated by reference herein. The staple forming recesses ofthe anvil, or the staple pushers, or both, can be configuredaccordingly, to form the staples in the desired shape and size.

The removable and replaceable staple cartridge assembly 115 can furtherinclude a chip assembly 362. (see FIGS. 27 and 28 ). A correspondingboard assembly 380 (FIGS. 25 and 26 ) is disposed on the tool assemblyof the loading unit 116, and may be disposed on the channel 120. Thetool assembly board assembly 380 can be configured as discussed above inconnection with the adapter board assembly 50 of the adapter coupler 27.The tool assembly board assembly 380 is configured to be securelymounted on a wall of the channel 120. This board assembly 380 ispositioned such that when cartridge assembly 140 is secured to thechannel 120 of the loading unit, the chip assembly 362 engages the boardassembly 380 mounted on the channel. (See FIGS. 29-31 ). FIGS. 27 and 28show the relationship between the chip assembly and the staple cartridgebody 140, whereas FIG. 29 shows the relationship between the chipassembly 362 and the support plate 111 a.

In more detail, chip assembly includes a body 337 and a pair of contactmembers 340 a, 340 b (collectively, contact members 340) connected to achip 336 disposed in the body. Body 337 defines a rectangular memberhaving flexible arms with snap features 337 a thereon. The flexible armsare configured to be securely received within a recess 331 defined by inthe cartridge body. Chip 336 is in electrical communication with contactmembers 340.

Chip 336 includes any chip capable of storing information concerning thestaple cartridge assembly 115. The chip can be the same as or similar tothe chip of authentication board assembly 30. In any of the embodimentsdisclosed herein, any of the chips can store information such as,without limitation, cartridge size, staple arrangement, staple linelength (or cartridge length), date of manufacture, expiration date,compatibility characteristics, a unique identifier (e.g., a serialnumber), and/or number of uses, as well as whether or not the staplecartridge assembly has been used. Such information can be transmitted tothe controller in the handle assembly 112, or to another computercomponent through an appropriate bus, pin connection, wireless means,etc. In some embodiments, chip 336 includes an erasable programmableread only memory (“EPROM”) chip. The controller in the handle assemblycan write information to the chip 336. In this manner, the handleassembly 112 may adjust the firing forces, firing stroke, and/or otheroperational characteristics thereof in accordance with the informationconcerning the staple cartridge assembly that are transmitted from chip336. The handle assembly 112 can communicate to chip 336 that the staplecartridge assembly has been used, which can prevent reloading or reuseof an expended reload assembly, or any other unauthorized use. Theinformation stored in any of the components in the surgical system canbe encrypted using private keys, public keys, and/or secure hashalgorithms.

The board assembly 380 also has a pair of contacts 380 a and 380 b and abody 381. The board assembly is mounted for contact with the chipassembly 362 when the staple cartridge assembly is properly mounted inthe channel 120. The contacts 380 a, 380 b, 340 a, and 340 b have anL-shaped configuration as seen in the figures so that they mayresiliently engage one another. The body 381 can define a snap feature382 that is provided to engage a hole 383 in the channel to securelymount the board assembly. The board assembly is appropriately connectedto a bus, wires, or has a wireless communicator for transmittal of theinformation from chip assembly 362 to the controller in the handleassembly, or any other computer device.

In any of the embodiments disclosed herein, a lockout mechanism 500 isdisposed in the loading unit. The loading unit may be configured asdiscussed above. Furthermore, the present disclosure is directed to aremovable assembly having the lockout, or a loading unit having thelockout.

The lockout mechanism 500 includes a latch 2010 and at least one spring2030, and is configured to prevent re-firing of a staple cartridgeassembly 115 or staple cartridge 26, and also prevent distal translationof a drive beam after the staple cartridge has been fired and prior toloading of another cartridge assembly 115. The lockout mechanism 500 isshown alongside the sled 148 and mounting assembly 2020 in FIG. 50 . Theat least one spring 2030 is mounted on a distally facing surface 2031.For example, recesses are formed in surface 2031 for receiving springs2030. Corresponding posts are provided on a proximally facing surface ofthe latch 2010. The latch is configured to be pivotable within theloading unit, and includes at least one prong 2012, a rear portion 2014,and a supporting portion 2016. The latch is configured to pivot aroundthe supporting portion 2016, shown in FIGS. 50 and 51 as two downwardlydepending features, and is biased by the spring or springs 2030. Thesled 148 has a hole or recess for receiving the at least one prong 2012when the latch and drive beam are in their initial positions. (see FIG.52 ). The drive beam 2039 can interact with, or include, a dynamicclamping member 2040 having an upper flange 2042, lower flange 2044, andknife blade 2046. (see FIG. 53 ).

In the initial position, the latch 2010 is biased in a forward or distaldirection, with the rear portion 2014 in contact with an edge 2039 a onthe drive beam 2039, preventing further rotational movement of thelatch. As the drive beam and dynamic clamping member are moved in aforward or distal direction, the dynamic clamping member pushes the sleddistally. A rear portion 148 a of the sled pushes the prong or prongs2012, tilting the latch against the bias of the at least one spring2030. This removes the rear portion 2014 from the area near the edge2039 a, and allows the drive beam and dynamic clamping member to moveforward. After the dynamic clamping member passes the latch 2010, thelatch rotates forwardly under the influence of the spring. (see FIG. 57).

After the dynamic clamping member and sled have fired the staples fromthe cartridge 140, the dynamic clamping member is moved proximally,leaving the sled at the distal end of the cartridge 140 and cartridgeassembly 115. The dynamic clamping member can move past the latch 2010,as cam surface 2041 moves the latch out of the path of travel (see FIG.57 ). Once the dynamic clamping member returns to the initial position,the latch 2010 will prevent another forward movement of the dynamicclamping member 2040. The latch rear portion 2014 is in a position toengage another edge 2039 b of the drive beam. (see FIG. 57 ). If theloading unit is of the type that accepts removable and replaceablestaple cartridge assemblies 115, the cartridge assembly 115 can beconfigured to return the latch 2010 to the initial position, so that thedrive beam and dynamic clamping member can again be moved distally tofire another set of staples.

As discussed above, any of the embodiments disclosed herein can includea chip assembly 360 on a surgical stapling loading unit, like loadingunit 116, that has information on it concerning the lockout mechanism,such as the lockout mechanism discussed above. Furthermore, informationcan be stored on the chip 361 concerning the lockout mechanism. Forexample, the fact that the lockout mechanism was engaged can be recordedin chip assembly 360 and/or chip assembly 362 by the controller in thehandle. The controller in the handle can include a memory for storinginformation, including a processor, and other computer components. Thecontroller can also include a current meter, or ammeter, to measure thecurrent in the motor of the handle assembly. The controller can beprogrammed to record the peak current reached during use of the loadingunit and/or staple cartridge assembly, and can record that peak currenton any of the chips or other computer components in the system. A peakcurrent reached after the staples have been fired can be an indicationthat the loading unit was attempted to be fired a second time before afresh staple cartridge assembly was mounted in the loading unit.Alternatively, the lockout mechanism can include a sensor such as, forexample, on the latch. It is contemplated that the surgical system caninclude loading units that do not have a lockout mechanism like the onediscussed above. The fact that the loading unit does not have a lockoutmechanism can be stored in chip 361.

The handle assembly can also include an encoder that determines how manyrotations of the motor output shaft have been made, which can be used todetermine a position of drive bars, linkages, cables, etc., in theadapter assembly, the firing bar in the loading unit, or othercomponents. Alternatively, other sensors can be used to determine theposition of various components in the surgical system.

The adapter assembly disclosed herein, in any of the embodimentsdisclosed herein, can be configured as disclosed in U.S. PublishedApplication No. 2011/0174099 A1, the entire disclosure of which ishereby incorporated by reference herein. The motor in the handleassembly provides a rotational output on a rotating shaft and theadapter is configured to transform that output to a linearly movinglinkage or bar, and can also provide drive to an articulation linkage inthe proximal body portion 118 of the loading unit 116. The handleassembly and/or adapter assembly can be configured as disclosed in U.S.Published Application Nos. 2014/0012289 A1 and 2014/0110453 A1, theentire disclosures of which are hereby incorporated by reference herein.

Any of the embodiments described in connection with FIGS. 1 through 57can include the protocol and/or multiplexor discussed herein. In any ofthe embodiment disclosed herein, the motor in the handle assembly orhousing may be any electrical motor configured to actuate one or moredrives (such as rotatable drive connectors). The motor is coupled to abattery, which may be a DC battery (e.g., rechargeable lead-based,nickel-based, lithium-ion based, battery etc.), an AC/DC transformer, orany other power source suitable for providing electrical energy to themotor.

FIG. 58 shows a surgical system 1010 including a surgical device 1100that is selectively connectable to an adapter 1200, in turn, selectivelyconnectable to a surgical loading unit 1300. Such a system is disclosedin U.S. patent application Ser. No. 14/172,109, the disclosure of whichis hereby incorporated herein by reference in its entirety. It iscontemplated that a variety of surgical reload assemblies 1300 can beused in connection with the system 1010, including electrosurgicalreloads, circular stapling loading units, linear stapling loading units,suturing devices, etc.

Adapter 1200 is configured to connect at least one configuration of thesurgical reload assembly 1300 to the surgical device 1100, wherein thesurgical device 1100 may provide two rotating drive outputs, which canbe converted into different rotational drives, linear drives, etc., sothat different configurations of the surgical loading units 300 can beoperated by the surgical device 1100. As seen in FIG. 58 , the adapter200 generally includes a proximal coupling assembly 1210 at a proximalend thereof and a distal coupling assembly 1230 at a distal end thereof.

Surgical device 1100, as shown in FIG. 58 , includes a handle housing1102 having a lower housing portion 1104, an intermediate housingportion 1106 extending from and/or supported on a lower housing portion1104, and an upper housing portion 1108 extending from and/or supportedon an intermediate housing portion 1106. Handle housing 1102 supports atrigger housing 1107 on a distal surface or side of intermediate housingportion 1108. Upper housing portion 1108 defines a connecting portion1108 a configured to accept a corresponding drive coupling assembly 1210of adapter 1200. Lower housing portion 1104 of the handle housing 1102provides a housing in which a battery 1156 is removeably situated.Battery 1156 is configured to supply power to any of the electricalcomponents of the surgical device 1100. Lower housing portion 1104defines a cavity (not shown) into which the battery 1156 is inserted.Lower housing portion 1104 includes a door 1105 pivotally connectedthereto for closing the cavity of the lower housing portion 1104 andretaining the battery 1156 therein.

Surgical loading unit 1300 generally includes a proximal body portion1302 and a tool assembly 1304. Proximal body portion 1302 is selectivelyconnectable to the distal coupling assembly 1230 of the adapter 1200,and the tool assembly 304 is pivotally attached to a distal end ofproximal body portion 1302. Tool assembly 1304 includes an anvilassembly 1306 and a cartridge assembly 1308. In the illustrativeembodiment shown in FIG. 58 , the surgical loading unit 1300 is a linearstapling reload with a separately removable and replaceable cartridge,and the adapter 1200 is configured to drive the various components ofthe reload assembly 1300 in order to clamp tissue, fire staples, and cutthe tissue. An example of a surgical reload assembly having a removableand replaceable staple cartridge assembly is disclosed in U.S. patentapplication Ser. No. 13/280,880, the disclosure of which is incorporatedherein by reference in its entirety.

Surgical device 1100 includes a controller 1080 that contains the devicesoftware that operates the surgical device 1100, the adapter 1200,and/or the surgical loading unit 1300. Connections to the varioushardware and software interfaces of the surgical system 1010, andelectrical connections relating to the controller 1080, are described inU.S. patent application Ser. No. 13/331,047, the disclosure of which ishereby incorporated herein by reference in its entirety.

The presently-disclosed PCB utilizes a multiplexing scheme andmicroprocessor to combine 1-wire data and UART (universal asynchronousreceiver/transmitter) transmit and UART receive onto a single mechanicalpin or other physical connector, so that data can be read from the chipsin the various components of the system in an efficient manner. In someembodiments, the chips in each component may be Dallas one wire chips,which have a single data wire and a ground wire The presently-disclosedPCB embodiments require two 2 wires (data and ground), for example, asopposed to four wires required to implement using standard topology. Thepresently-disclosed communication protocol may increase reliabilitybecause there are fewer mechanical parts subject to corrosion and/orfailure, particularly where PCB pins may be exposed to blood. Theteachings of the present disclosure may apply to a variety of surgicaldevices that include a bus system.

FIGS. 59 and 60 show a PCB that includes a microprocessor 1020, amicrochip 1030, and a bus 1010, which is configured to receive signalsfrom a signal source 1120, e.g., controller 1080 of the surgical device1100. Microchip 1030 is configured to provide device authentication, andmay utilize a one-wire data interface. Microchip 1030 iscommunicatively-coupled through the bus 1010 to the signal source 1120and communicatively-coupled to the microprocessor 1020. As shown, themicrochip is the DS28E15 chip from Maxim Integrated, but other chips maybe used. Microprocessor 1020 is capable of demultiplexing transmit andreceive lines. It is contemplated that the signal source can be someother computer component, such as an operating room computer system orrobotic surgical system.

Based upon communications between microprocessor 1020 and the signalsource 1120, the microprocessor 1020 controls bus selection. In someembodiments, a receive mode and a transmit mode over the bus 1010 arecontrolled by multiplexing on the microprocessor 1020 utilizing a groundwire 1012 of the microchip 1030. In order to transmit over the bus 1010,the ground wire 1012 is turned off, and the microprocessor 1020 selectsthe transmit mode. In order to receive over the bus 1010, the groundwire 1012 is turned on, and the microprocessor 1020 selects the receivemode.

Hereinafter, a method of communicating data through a bus in accordancewith the present disclosure is described with reference to FIG. 60 . Itis to be understood that the steps of the method provided herein may beperformed in combination and in a different order than presented hereinwithout departing from the scope of the disclosure.

FIG. 61 is a flowchart illustrating a method of communicating datathrough a bus in accordance with an embodiment of the presentdisclosure. In step 1410, a microprocessor 1020 capable ofdemultiplexing transmit and receive lines is provided.

In step 1420, a microchip 1030 configured to provide deviceauthentication is provided. Microchip 1030 is communicatively-coupledthrough a bus 1010 to a signal source 1120 and communicatively-coupledto the microprocessor 1020. Microchip 1030 may utilize a one-wire datainterface. The signal source transmits to microchip 1030 the combineddata from microchips in the surgical system, such as for example theloading unit, staple cartridge assembly, and/or adapter.

In step 1430, a receive mode and a transmit mode over the bus 1010 arecontrolled by multiplexing on the microprocessor 1020 utilizing a groundwire 1012 of the microchip 1030.

In step 1440, at least one signal is received from the signal source1120 using the receive mode over the bus 1010. In some embodiments,receiving at least one signal from the signal source 1120 using thereceive mode over the bus 1010 includes turning on the ground wire 1012of the microchip 1030. Receiving at least one signal from the signalsource 1120 using the receive mode over the bus 1010 may further includeselecting the receive mode utilizing the microprocessor 1020.

In step 1450, at least one signal is transmitted from the signal source1120 using the transmit mode over the bus 1010. In some embodiments,transmitting at least one signal from the signal source 1120 using thetransmit mode over the bus 10 includes turning off the ground wire 1012of the microchip 1030. Transmitting at least one signal from the signalsource 1120 using the transmit mode over the bus 1010 may furtherinclude selecting the transmit mode utilizing the microprocessor 1020.

In another embodiment of a method of communicating data through a bus inaccordance with the present disclosure, the method includes:authenticating a surgical device, or component of a surgical systemutilizing a microchip 1030 communicatively-coupled through a bus 1010 toa signal source 1120 and communicatively-coupled to a microprocessor1020 capable of demultiplexing transmit and receive lines; andcontrolling a receive mode and a transmit mode over the bus 1010 bymultiplexing on the microprocessor 1020 utilizing a ground wire 1012 ofthe microchip 1030. Authenticating the surgical device may includeutilizing a one-wire data interface of the microchip 1030.

Various embodiments of the above-described PCBs utilize a receive modeand a transmit mode over a bus which is controlled by multiplexing on amicroprocessor utilizing a ground wire of a microchip configured toprovide device authentication.

It is contemplated that the protocol and/or multiplexor can be used toreduce the bus to two wires instead of three or four, from four wires tothree, etc., reducing the communication connectors or pins to two orthree, respectively.

FIG. 62 is an exemplary coupling assembly for the surgical handleassembly 1100 and adapter assembly 1200, which can be used in any of theembodiments disclosed herein. A similar coupling assembly is providedbetween the adapter assembly and the loading unit. The connectingportion 2108 a of surgical instrument 2100 has a cylindrical recess 2108b that receives a drive coupling assembly 2210 of adapter assembly 2200when adapter assembly 2200 is mated to surgical instrument 2100.Connecting portion 2108 a houses three rotatable drive connectors 2118,2120, 2122.

When adapter 2200 is mated to surgical instrument 2100, each ofrotatable drive connectors 2118, 2120, 2122 of surgical instrument 2100couples with a corresponding rotatable connector sleeve 2218, 2220, 2222of adapter 2200 as shown in FIG. 62 . In this regard, the interfacebetween corresponding first drive connector 2118 and first connectorsleeve 2218, the interface between corresponding second drive connector2120 and second connector sleeve 2220, and the interface betweencorresponding third drive connector 2122 and third connector sleeve 2222are keyed such that rotation of each of drive connectors 2118, 2120,2122 of surgical instrument 2100 causes a corresponding rotation of thecorresponding connector sleeve 2218, 2220, 2222 of adapter assembly2200.

The mating of drive connectors 2118, 2120, 2122 of surgical instrument2100 with connector sleeves 2218, 2220, 2222 of adapter assembly 2200allows rotational forces to be independently transmitted via each of thethree respective connector interfaces. The drive connectors 2118, 2120,2122 of surgical instrument 2100 are configured to be independentlyrotated by drive mechanism 2160. In this regard, the controller in theinstrument or handle assembly 2100 selects which drive connector orconnectors 2118, 2120, 2122 of surgical instrument 2100 is to be drivenby a drive mechanism in the handle assembly or surgical instrument.

Each of drive connectors 2118, 2120, 2122 of surgical instrument 2100has a keyed and/or substantially non-rotatable interface with respectiveconnector sleeves 2218, 2220, 2222. The selective rotation of driveconnector(s) 2118, 2120 and/or 2122 of surgical instrument 2100 allowssurgical instrument 2100 to selectively actuate different functions ofend effector/loading unit, such as loading unit 1300. Such functionsinclude selective and independent opening and closing of tool assemblyof loading unit such as loading unit 1300, driving of stapling and/orcutting, articulation of a tool assembly of a loading unit, and/orrotation of shaft 1302 and or shaft of the adapter assembly about alongitudinal axis thereof.

The coupling assembly also has communication connectors 2501 and 2502,which are shown in a pair in FIG. 62 . In embodiments using themultiplexing scheme and/or multiplexor discussed above, signals fromthree chips (e.g., staple cartridge chip, loading unit chip, and adapterassembly chip) can be combined and communicated to a microprocessor(such as the one shown in FIG. 60 ). The controller of the surgicalsystem can then use the data from such chips as discussed above. Incertain preferred embodiments the communication connectors are singularconnectors instead of the pair shown. In any of the embodimentsdisclosed herein, there may also be force and/or load sensors thatconnect to the microprocessor. In any of the embodiments disclosedherein the microprocessor such as microprocessor 1020 can transmit datato the one or more chips (staple cartridge chip, loading unit chip,and/or adapter assembly chip). Such data can include an indication thatthe staples have been fired, and/or incrementing a counter for thenumber of uses of the particular component. Such data can include themaximum drive force experienced and/or the position of the driveassembly/drive beam, etc.

Although the illustrative embodiments of the present disclosure havebeen described herein with reference to the accompanying drawings, it isto be understood that the disclosure is not limited to those preciseembodiments, and that various other changes and modifications may beeffected therein by one skilled in the art without departing from thescope or spirit of the disclosure.

What is claimed is:
 1. A surgical system, comprising: a handle assembly;a controller disposed within the handle assembly and configured tocontrol operation of the surgical system; an adapter assemblyreleaseably coupled to the handle assembly; and a surgical staplingloading unit configured to support a staple cartridge assembly at adistal end thereof, the surgical stapling loading unit releasablycoupled to the adapter assembly, wherein the surgical stapling loadingunit includes: a microchip in communication with the controller over abus connection, the microchip storing data indicative of one or moreproperties of the surgical stapling loading unit or the staple cartridgeassembly; and a microprocessor disposed within the surgical staplingloading unit and in communication with the microchip over a single-wirebus connection separate from the bus connection between the microchipand the controller, the microprocessor including a ground wire andconfigured to switch the microchip between a receive mode and a transmitmode by switching the ground wire between ON and OFF positions.
 2. Thesurgical system according to claim 1, wherein the one or more propertiesof the staple cartridge assembly includes whether the staple cartridgeassembly is articulable relative to the surgical stapling loading unit.3. The surgical system according to claim 2, wherein the controllerreads the data and prevents actuation of an articulation link in theadapter assembly or the surgical stapling loading unit if the dataindicates that the staple cartridge assembly is not articulable.
 4. Thesurgical system according to claim 1, wherein the adapter assemblyincludes an adapter chip in communication with the microprocessor, theadapter chip storing data indicative of one or more properties of theadapter assembly.
 5. The surgical system according to claim 4, whereinthe microprocessor is configured to switch the adapter chip between areceive mode and a transmit mode.
 6. A surgical stapling loading unitfor use in a surgical system, comprising: a staple cartridge assembly; amicrochip storing data indicative of one or more properties of thestaple cartridge assembly, the microchip configured to communicate, overa bus connection, with a controller configured to control operation ofthe surgical system; and a microprocessor in communication with themicrochip over a single-wire bus connection separate from the busconnection between the microchip and the controller, the microprocessorincluding a ground wire and configured to switch the microchip between areceive mode and a transmit mode by switching the ground wire between ONand OFF positions.
 7. The surgical stapling loading unit according toclaim 6, wherein the microprocessor is configured to multiplex data fromthe microchip.
 8. The surgical stapling loading unit according to claim6, wherein the second bus is a one-wire data interface.
 9. The surgicalstapling loading unit according to claim 6, wherein the one or moreproperties of the staple cartridge assembly includes whether the staplecartridge assembly is articulable relative to the surgical staplingloading unit.
 10. The surgical stapling loading unit according to claim9, wherein the controller reads the data and prevents actuation of anarticulation link in an adapter assembly associated with the surgicalstapling loading unit if the data indicates that the staple cartridgeassembly is not articulable.
 11. A surgical stapling loading unit foruse in a surgical system, comprising: a staple cartridge assembly; and amicrochip storing data indicative of one or more properties of thestaple cartridge assembly, the microchip configured to communicate overa single-wire bus connection with a microprocessor having a ground wireand over a bus connection separate from the single-wire bus connectionwith a controller configured to control operation of the surgicalsystem, wherein the microprocessor is configured to switch the microchipbetween a receive mode and a transmit mode by switching the ground wirebetween ON and OFF positions.
 12. The surgical stapling loading unitaccording to claim 11, further including an adapter assembly having oneor more properties, the adapter assembly including an adapter chip incommunication with the microprocessor, the adapter chip storing dataindicative of one or more properties of the adapter assembly.
 13. Thesurgical stapling loading unit according to claim 12, wherein themicroprocessor is configured to switch the adapter chip between areceive mode and a transmit mode.